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ii Revised April-2017
Site Considerations for Equipment Installation, Grounding, and Wiring Manual
Contents
Chapter 1 – Overview 1
1.1 Introduction ......................................................................................................................................... 1
1.2 Major Topics ....................................................................................................................................... 1
Chapter 2 – Protection 3
2.1 Protecting Instrumentation Systems .................................................................................................. 3
2.1.1 Quality is Conformance to Requirements ............................................................................ 3
2.2 Protecting Equipment and Personnel................................................................................................. 4
2.2.1 Considerations for the Protection of Personnel ................................................................... 4
2.2.2 Considerations for the Protection of Equipment .................................................................. 5
2.3 Other Site Safety Considerations ....................................................................................................... 6
Chapter 1 – Overview
1.1 Introduction
This document provides information pertaining to the installation of
RTUs, controllers, and flow computers from Emerson Remote
Automation Solutions including the ControlWave family of flow
computers and RTUs and the FB1100, FB1200, FB2100, and FB2200
flow computers. More specifically, this document provides information
covering reasons, theory and techniques for protecting your personnel
and equipment from electrical damage. Your instrumentation system
affects the quality of service provided by your company and many
aspects of its operational safety. Loss of instruments means lost
production and profits as well as increased expenses.
Chapter 2 – Protection
In This Chapter
Some of the items that a service person should consider before ever
going onsite can be ascertained by simply asking questions of the
Figure 3-3. Basic Ground Bed Soil Test Setup with Additional Ground Rods
Figure 3-2 shows the test setup for “good soil” conditions. If the
Megger* reads less than 5 ohms, the ground is good. The lower the
resistance, the better the earth ground. If the Megger reads more than 10
ohms, the ground is considered “poor”. If a poor ground is indicated,
10 Grounding and Isolation Revised April-2017
Site Considerations for Equipment Installation, Grounding, and Wiring Manual
one or more additional ground rods connected 10 feet from the main
ground rod should be driven into the soil and interconnected via bare
AWG 0000 copper wire and 1” x ¼-20 cable clamps as illustrated in
Figure 3-3). *
Note: Megger is a Trademark of the Biddle Instrument Co. (now
owned by AVO International). Other devices that may be
used to test ground resistance are “Viboground”; Associated
Research, Inc., “Groundmeter”; Industrial Instruments, Inc.,
and “Ground-ohmer”; Herman H. Sticht Co., Inc.
If the Megger still reads more than 10 ohms, mix a generous amount of
cooking salt, ice cream salt or rock salt with water and then pour about
2.5 to 5 gallons of this solution around each rod (including the test
rods). Wait 15 minutes and re-test the soil. If the test fails, the soil is
poor and a ‘Poor Soil Ground Bed’ will have to be constructed.
Figure 3-4 shows a typical poor soil ground bed electrode. A poor soil
ground bed will typically consists of four or more 10-foot long
electrodes stacked vertically and separated by earth. Figure 3-5 shows
the construction of a poor soil ground bed. For some poor soil sites, the
ground bed will be constructed of many layers of “capacitive couplings”
as illustrated. In extremely “poor soil” sites one or more 3’ by 3’ copper
plates (12 gauge or 1/16” thick) will have to be buried in place of the
electrodes.
Sandy soil, either wet or dry, may have had its soluble salts leached out
by rain water, thereby reducing conductivity of the ground. High
currents from lightning strikes could also melt sand and cause glass to
form around the ground rod, rendering it ineffective. A buried
counterpoise or copper screen is preferred for these installations along
with regular applications of salt water.
Units with phone modems require the use of a lightning arrester. The
lightning arrester must be situated at the point where the
communication line enters the building.
General Considerations
The following considerations are provided for the installation of
controller/flow computer system grounds:
Size of ground wire (running to earth ground should be #4
AWG. It is recommended that stranded copper wire is used for
this application and that the length should be as short as possible.
This ground wire should be clamped or brazed to the ground
bed conductor (that is typically a stranded copper AWG 0000
cable installed vertically or horizontally).
The wire ends should be tinned with solder prior to installation.
The ground wire should be run such that any routing bend in
the cable has a minimum radius of 12-inches below ground and
8-inches above ground.
The ground conductor connects between the Ground Lug and a known
good earth ground. Connect the cases of Temperature Transducers,
Pressure Transmitters, etc., to the known good earth ground. If the
mounting 2-inch pipe is in continuity with the pipeline it will have to be
electrically isolated from the flow computer. Use a strong heat-shrink
material such as RAYCHEM WCSM 68/22 EU 3140. This black tubing
will easily slip over the 2-inch pipe and then after uniform heating (e.g.,
with a rose-bud torch) it electrically insulates and increases the strength
of the pipe stand.
Chart 1 Chart 2
I “A” LAT.° “B”
5 8 25 .170
10 26 30 .200
20 85 35 .236
30 169 40 .280
40 275 45 .325
50 402
60 548
70 712
80 893
90 1069
100 1306
Note for these charts:
I = Thunderstorm Days Per Year (Isokeraunic Number)
A = Stroke activity for associated Isokeraunic Area
B = Height/Stroke coefficient for associated latitude
Note: The Isokeraunic activity numbers connoted as “I”, “A” and “B”
in Charts 1 and 2 above are provided for the continental United
States. Isokeraunic data for various countries is available from
various federal or state Civil Engineering or Meteorological
organizations. This information is typically available from
manufacturers of lightning strike protection equipment (such as
Lightning Arresters).
Since controllers and flow computers use DC operated systems that are
isolated from AC grids, they are typically immune to lightning strikes to
power lines or power equipment (except for inductive flashover due to
close installation proximity). However, once a radio or modem has been
interfaced to the controller or flow computer, the possibility of damage
due to a lightning strike on power or telephone lines or to a radio
antenna or the antenna’s tower must be considered. It is recommended
that the additional lightning protection considerations listed below be
followed for units installed in areas with a high possibility or history of
stroke activity.
Units interfaced to a modem: In series with the phone line (as far
away as possible from the equipment) - for indoor installations the
lightning arrester should typically be located at the point where the line
enters the structure.
Units interfaced to a radio: Mount antenna discharge unit (lightning
arrester) as close as possible to where the lead in wire enters the
structure. See Antenna Caution below.
will all rise together to the one million volt peak level (for example) and
will all decay back down together. So long as there is no voltage
differential (taken care of by protectors and ground interconnections,
there will be no current flow through the equipment and therefore
no resulting equipment damage.
Figure 4-4. Protecting Equipment with Lightning Arresters and Surge Protectors
5.1 Overview
This section provides information pertaining to good wiring practices.
Installation of Power and “Measurement & Control” wiring is
discussed. Information on obscure problems, circulating ground and
power loops, bad relays, etc. is presented. Good wire preparation and
connection techniques along with problems to avoid are discussed.
Be careful to use wire that is appropriately sized for the load. Refer to
equipment manufacturer’s specifications and the National Electrical
Code Handbook for information on wire size and wire resistance. After
installing the field wiring, test each load to determine if the correct
voltage or current is present at the load. If you know the resistance of
the field wires (Circular Mills x Length) you should be able to calculate
the load voltage. Conversely, if you know the minimum load voltage
and current, you should be able to derive the maximum voltage loss
that is allowable due to line resistance and then the correct wire size.
Referring to Figure 5-2, a relay that is picked by 100 mA, with a loop
supply voltage of 24V
and a total line resistance of 20 ohms, the load voltage (voltage across
the relay) should be:
If installing stranded or braided wiring that has not been tinned, be sure
to tightly twist the end (in the same direction as manufactured) and then
trim off any frizzed wires.